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1500 r.p.m(Ratio-5/1)
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1500 r.p.m(Ratio-5/1)
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1500 r.p.m(Ratio-60/1)
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GearboxA worm drive is a gear arrangement in which a worm (which
is a gear in the form of a screw) meshes with a worm gear (which is
similar in appearance to a spur gear,and is also called a worm
wheel). The terminology is often confused by imprecise use of the
term worm gear to refer to the worm, the worm gear, or the worm
drive asa unit.
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Like other gear arrangements, a worm drive can reduce rotational
speed or allow higher torque to be transmitted. The image shows a
section of a gear box with aworm gear being driven by a worm. A
worm is an example of a screw, one of the six simple machines
Gear box is required for:-
1. House and hold the gears in place 2. Protect the gear
mechanism from any mishap. 3. Protection from dust etc 4. To keep
the lubrication
Gears are required for:-
1. To reduce / increase the rpm. 2. Change the direction of
rotation (clockwise / anti clockwise.) 3. Shift the axis of
rotation.(linear or angular)
Control over power output, by means of the throttle pedal,
simply regulates the rate at which the engine is doing work: at
very high speeds,the power output will becorrespondingly high but
the torque output can at the same time be significantly less than
at considerably lower speeds. In other words, maximum torque may
beavailable over only a very limited speed range. Consequently, one
needs to be able to regulate both the power output and the speed
range of the engine relative to therange of speeds over which the
vehicle is at any given time likely to be required to operate. Only
in this way can the torque at the wheels be balanced against
demandsfor either a steady speed uphill or downhill, or on the
level, or for acceleration or deceleration. A gearbox is necessary,
therefore, so that the driver can regulate torqueby selecting the
appropriate speed range or, in other words, the vehicle speed at
which maximum torque is obtainable.
When a vehicle is moving at a uniform speed, the driving force,
or tractive effort, at the wheels must be such as to exactly
balance the sum of three categories ofvariable forces tending to
oppose the motion. If it is greater, the car will accelerate, and
if it is smaller, it will decelerate until a balance is obtained.
Such a balance willbe established eventually, because two of the
forces vary with speed.
The three forces are:-
(1) aerodynamic, or air, resistance;
(2) gradient resistance, which can be either positive or
negative;
(3) rolling resistance.
Gearbox selectionGearbox selection will be done in two
stages:
1) Selection of gearbox type2) Determining the size of the
selected gearbox type
Selection of Gearbox Type
The gearbox type suitable for the driven machine is determined
during project phase. The technical staff designing the project
decides on the type of gearboxaccording to his past experiences or
examining applications done before.
For systems requiring less power, motor gears are the
recommended solution. Motor gears are less expensive and are easily
mounted. Shaft mounted gearboxesare also preferred due to same
reasons.
Gearbox transmission ratios, powers and summary information on
gear systems are given on Catalog.These are necessary in selection
of a Gearbox.
Determining the size of the selected gearbox
Gearbox size can be determined with the help of the gearbox
power tables. For each gearbox type a separate power table is laid
out. The table shows the maximumpower (kW) a given gearbox size can
transmit according to the input speed and transmission ratio. The
output torque the gearbox can transmit is also given in aseparate
table.
The power and torque values given in tables are nominal values.
The power and torque needed for the driven machine should be less
than the nominal power andtorque the gearbox can transmit so that
the gearbox can operate at a certain safety.
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The power Nre, the gearbox should transmit, is determined by
multiplying the power Nd needed for the driven machine by the
operation safety factor. The nominalpower of the selected gearbox
should be equal to or more than the Nre value.
Please find below the method to calculate the operation safety
factor.
Operation safety factor (F):
Coefficients determining the factor:
1) The coefficient for the driven machine, fd2) The coefficient
for the driving motor, fm3) The coefficient for the daily operation
time, ft4) The coefficient for the start-up number, fs
Operation safety factor F is attained by multiplying the four
coefficients: F = fd . fm . ft . fs
The driven machine coefficient (fd)
This coefficient depends on the type of driven machine. Driven
machines can be classified in four main groups according to their
level of shock loading and momentof inertia.
Uniformly operating machines without shock loading: For machines
with constant power demand, which operate without shock loading and
without suddenmoment increase, the coefficient fd is taken as
1.
Machines with medium shock loading: For machines which operate
with medium shock loading and where load increases or decreases by
at most 50%, thecoefficient fd is taken as 1.5.
Machines with heavy shock loading and high moment of inertia:
For machines with high inertia which operate with heavy shock
loading and where load increases ordecreases by at most 100%, the
coefficient fd is taken as 2.
Machines with very heavy shock loading and very high moment of
inertia: The coefficient fd is taken as 2.5-3 for this group.
The types of machines within these four main groups are given in
operation safety factor table.
Driving motor coefficient ( fm )
This coefficient is determined according to the type of motor
driving the system. There are three main groups:
1.Group: Electric motors (Asynchronous, synchronous, direct
current motors), steam turbines, hydraulic motors. The fm for this
group is taken as 1.
2.Group: Internal combustion, 4 - 6 cylinder engines (gasoline
or diesel), water turbines. The fm for this group is taken as
1.25.
3.Group: Internal combustion, 1 - 3 cylinder engines (gasoline
or diesel.) The fm for this group is taken as 1.5.
Daily operation time coefficient ( ft )
If the daily operation time is between 3 - 10 hours, the ft
coefficient is taken as 1.If the daily operation time is less than
3 hours, the ft coefficient is taken as 0.8.If the daily operation
time is between 10 - 24 hours, the ft coefficient is taken as
1.25.
Start-up number coefficient ( fs )
If the system makes at most five start-ups in an hour, the
coefficient fs is taken as 1.
If the system makes more than five start-ups in an hour, the
coefficient fs is taken between 1.25 2. In this case, special
precautions might be needed. Connectingthe gearbox to the motor
with hydraulic or electro-mechanical coupling will reduce the
effect of shocks during stop-starts.
An example for operation safety factor calculation
The safety factor (F) for a system operating 24 hours daily with
an electric motor, making at most five start-ups in an hour, with
moderate shocks:F = fm . fd . ft . fs = 1 . 1.5 . 1.25 . 1 =
1.875.F can be taken as 1.8 or 2.Operation safety factors (F) are
given in the table on page 19. In this table, driven machines are
classified into four groups; without shock loading, medium
shockloading, with heavy shock loading, and with very heavy shock
loading and high moment of inertia. This classification is a
guidance based on past experiences.Considering economical and
safety factors together, the operation safety factor can be taken
lower or higher than the value in the table.
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Thermal Power (Nt)
This is the power the gearbox can transmit without heating up.
Thermal power of gearbox depends on the size of external surface of
the gearbox housing, ambienttemperature, operation area (covered
place or open air) and the operation time in an hour (FD).Thermal
power values each gearbox size can transmit are given in gearbox
power tables. Thermal power values (Nt) given in tables are valid
for gearboxes operatingin a closed area, with 20 - 30C ambient
temperature and for continuous operation (FD = 100%).For 40C
ambient temperature, 75% of the value given; for 50C ambient
temperature, 60% of the value given in the table should be taken.If
the gearbox is operating 30 minutes in an hour (FD = 50%), Nt can
be increased by 25%. For an operation of 15 minutes in an hour (FD
= 25%), Nt can be increasedby 50%.If the gearbox is cooled with air
or the gearbox oil is cooled, thermal power can be increased by 10%
- 50% depending on the effect of the cooling.
Determination of gearbox size
Torque required for the driven machine is determined either by
calculation or by past experience. Speed suitable for driven
machine is again found either byexperience or by trial and error
method.The power required to obtain the required torque for the
driven machine at the selected speed is calculated in (kW) as:
Td (N.m) . nd (rpm)Nd = ____________________ 9550
Provided that torque required for the driven machine stays
constant, if the machine will operate at variable speed, power
required should be calculated considering thehighest speed.
Operation safety factor F can be taken from the table taking
into consideration type of driven machine, motor and daily
operation time.
The power gearbox should transmit (Nre) is obtained by
multiplying power required for driven machine (Nd) and operation
safety factor. The Nre value is the key forgearbox selection.Nre =
F . Nd
The power table for selected gearbox type shows the nominal
power Nn (kW) a given gearbox size can transmit according to the
input and output speed. The gearboxsize having a nominal power
greater than or equal to the Nre should be selected from the
table.
The Nre value calculated should be less than the thermal power
(Nt). ( Nre < Nt ).
If Nre is close to or greater than thermal power, gearbox should
be forced cooled. If there is no cooling possibility, a greater
size should be selected.
Hence, gearbox selection is completed.
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Double Output GearboxRefine Search
Double Input GearboxRefine Search
Double In/Out GearboxRefine Search
Gearbox with Motor FlangeRefine Search
Hollow O/P Shaft GearboxRefine Search
Double Reduction GearboxRefine Search
U-Standard GearboxRefine Search
O-Standard GearboxRefine Search
Double I/O Shaft GearboxRefine Search
Gearbox with RHBRefine Search
Shaft Mounted GearboxRefine Search
Heli-Worm GearboxRefine Search
SLA Units GearboxRefine Search
SDS Worm-GearboxRefine Search
HDS Worm-GearboxRefine Search
Motor Plate GearboxRefine Search
Cooling Tower GearboxRefine Search
SDS Worm GearboxRefine Search
HDS Worm GearboxRefine Search
